Steam Catalytic Cracking of Deasphalted Oil for Olefin Production
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Solution Overview
Problem
Conventional refinery systems require multiple complex unit operations to convert hydrocarbon feeds, such as crude oil, into valuable petrochemical products like olefins, which is inefficient and complex.
Innovation Solution
A process involving a Solvent Deasphalting Unit (SDA) to remove asphaltenes from hydrocarbon feeds, followed by steam catalytic cracking using a nano zeolite catalyst, simplifying the process and reducing the number of unit operations needed to produce olefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional refinery systems use multiple complex unit operations (distillation, hydrocracking, reforming, etc.) to convert crude oil to olefins, then the conversion is thorough and reliable, but the device complexity and number of unit operations increase significantly
Solution Approach 1:
The patent combines multiple conventional refinery unit operations (distillation, deasphalting, hydrocracking, reforming, and steam cracking) into an integrated process flow where the effluent from one unit directly feeds the next unit without intermediate storage or handling. This merging reduces the overall device complexity while maintaining conversion reliability through continuous processing.
Solution Approach 2:
The steam catalytic cracking unit serves multiple functions: it acts as both a hydrocracking unit and a reforming unit, producing olefins, gasoline blending components, and aromatic compounds (BTX) simultaneously. This multi-functionality reduces the need for separate dedicated units for each product stream.
2Adaptability or versatility
If conventional refinery systems employ multiple unit operations (atmospheric distillation, vacuum distillation, hydrocracking, reforming, aromatic recovery, etc.), then the product slate is comprehensive, but the number of equipment and processing steps increases
Solution Approach 1:
The patent segments the crude oil feed into different boiling point ranges through atmospheric and vacuum distillation, then processes each fraction through hydrocracking and reforming units to produce specific product slates. This segmentation allows comprehensive product coverage while organizing the complex process into manageable stages.
Solution Approach 2:
The patent utilizes parameter changes in the hydrocracking and reforming units (temperature, pressure, catalyst type) to adjust the product slate versatility. By modifying operating parameters rather than adding more units, the system achieves comprehensive product coverage with fewer equipment pieces.
3Productivity
If conventional refinery systems use multiple complex processing steps (distillation, hydrocracking, reforming, aromatic recovery, steam cracking), then the olefin production is maximized, but the processing time and operational complexity increase
Solution Approach 1:
The patent implements continuous processing where crude oil flows continuously through distillation, deasphalting, hydrocracking, reforming, and steam cracking units without batch interruptions. This continuity maximizes olefin production yield while reducing total processing time compared to batch operations.
Solution Approach 2:
The patent performs preliminary deasphalting and hydrocracking operations before the final steam cracking step that produces olefins. By preparing the feedstock in advance through these preliminary actions, the main olefin production step can operate at optimal conditions with maximum efficiency and reduced processing time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach increases the yield and production of valuable products like olefins with fewer equipment and process units, achieving higher efficiency and productivity compared to traditional methods.
Implementation Method 1
The SDA comprises a solvent that reacts with the hydrocarbon feed
Implementation Method 2
steam catalytically cracking the deasphalted oil stream in the steam catalytic cracking system in the presence of steam and a nano zeolite cracking catalyst
Data Source
AI summary
A process for producing olefins from the hydrocarbon feed includes introducing the hydrocarbon feed into a Solvent Deasphalting Unit (SDA) to remove asphaltene from the hydrocarbon feed producing a deasphalted oil stream, wherein the SDA comprises a solvent that reacts with the hydrocarbon feed, and the deasphalted oil stream comprises from 0.01 weight percent (wt. %) to 18 wt. % asphaltenes; introducing the deasphalted oil stream into a steam catalytic cracking system; steam catalytically cracking the deasphalted oil stream in the steam catalytic cracking system in the presence of steam and a nano zeolite cracking catalyst to produce a steam catalytic cracking effluent; and separating the olefins from the steam catalytic cracking effluent.